Rotary diverter sorter



Oct. 14, 1969 mow ETAL ROTARY DIVERTER SORTER 2 Sheets-Sweet 1 Filed Aug. 23, 1967 S m T e at m M v WW m .m m M .D vm "MA fly /F\\QN 0M, T JJ 7 Nu I! o 0 .Y Q B NM E mm wv a E v \E h A: .& Gm Q v swv 2 Eat ATTORNEY Oct. 14, 1969 J. RABINOW ET AL ROTARY DIVERTER SORTER 2 Sheets-Sheet 2 Filed Aug. 25, I967 I NVENTOR 8 Jacob Rab/now Joseph A. Genovese BY 44 M ATTORNE Y United States Patent U.S. Cl. 27164 6 Claims ABSTRACT OF THE DISCLOSURE Sorting apparatus which diverts articles from an input path to preselected branch paths by a rotary diverter disposed in an article path transition station at the juncture of the input and the branch paths. The diverter resembles a gear or a sprocket between whose teeth the forward edge of an article is accepted while the diverter is rotating clockwise or counterclockwise depending upon preselection of the branch path for the article being sorted. A bidirectional pneumatic system directionally synchronized with the diverter and operable at the transition station may be used to assist in diverting the articles by pneumatically urging them in the correct sorting direction as they approach the rotary diverter.

This invention relates to sorting and particularly to sorting apparatus for substantially flat articles which must be accurately and rapidly sorted in large numbers. A few examples are punch cards, postal letters, checks, coupons, transportation tickets or other documents read by optical or magnetic character reading mechines.

Certain sorting apparatus is designed for specific, uni form articles such as punch cards. Other apparatus must handle non-uniform articles such as postal letters or a variety of sheets. Many optical character reading machines are required to handle and sort cards, sheets of diiferent sizes and weights, envelopes and others. Our invention is primarily concerned with the more difficult task presented by the latter class of sorting apparatus although my invention is equally applicable to the former types of sorting apparatus.

Many prior sorting devices rely upon an oscillatory gate to direct each article to the correct destination. Other sorters use pneumatic means such as suction rollers or blowing ports for accomplishing the same result. There are a number of disclosures of sorting apparatus using a combination of mechanical and pneumatic means, the usual configuration having the pneumatic system assisting the mechanical in one or more of a variety of ways.

Although prior sorting devices are adequate, they leave considerable room for improvement. Keeping in mind that it is not uncommon for sorting devices to sort from ten to thirty articles per second, wear of mechanical parts poses a problem. This includes bearings, stops and other mechanical parts subject to shocks and hammering in the repetitious stop and start actuation of reciprocatory or oscillatory gate motions. The useful life of pneumatic valves expires sooner than desirable in undergoing such a large number of actuations over a relatively short period of, for example, a few months. i

In addition to the foregoing, most designers strive for quiet sorting apparatus. There is little than can be done to m uflle the aerodynamic noise of pneumatic valves. Oscillating gates can be cushioned to attenuate but not eliminate the noise.

Above all, a sorting device must be reliable ulider normal operating conditions, and it should be reliable under abnormal conditions. For example, some of the prior sorting devices are more likely to jam than others, and the consequences of a jam are more severe in cer- 3,472,506 Patented Oct. 14, 1969 tain sorters than in others. While it is probable that n sorter can be made totally and absolutely jam-proof, the likelihood of jams can be reduced and the consequence of a jam can be greatly minimized.

An object of our invention is to provide a sorting apparatus which partially or completely overcomes the above disadvantages of prior sorting equipment. This is accomplished by a sorting apparatus which uses a rotary diverter for diverting the articles to a selected path leading to the desired destination. Rotary motion, as opposed to the oscillatory motion of a gate, for example is comparatively shock and impact free even when the rotary diverter is required to stop and reverse directions. This contributes to longer life and quieter operation.

The pneumatic system of our invention is an optional feature, and it differs from prior pneumatic systems in that our pneumatic system uses no valves or valve elements to control the flow of air. Thus, there is no noise accompanying valve actuation (because valves are eliminated), and valve useful life is not a factor in our invention. As mentioned in the abstract, our pneumatic system includes a bi-directional blower directionally synchronized with the article diverter, e.g. driven by the same motor. By arranging air conductors from the blower ports to the left and right sides of the article path transition station, they alternately blow air to act upon the either side of the article as the diverter is driven clockwise or counterclockwise.

An important object of our invention is to provide a sorter which is less likely to encounter article jams than prior sorting devices owing to the rotary motion of the diverter which requires only coarse timing with respect to the approach of an article to be sorted.

Another object of our invention is to provide a sorter which does not appreciably damage or destroy articles in the event of a jam. Where various prior sorters will tear and even destroy jammed articles, our rotary diverter will simply brush aside a jammed article and harmlessly rotate near or against a surface thereof.

Other objects and features will become evident in following the description of the illustrated forms of the invention.

FIGURE 1 is a top view of our sorting apparatus.

FIGURE 2 is a side view of the apparatus.

FIGURES 3-31; are top schematic views showing articles being sorted without our pneumatic means.

FIGURES 4-4a are top views showing articles being sorted with the aid of our pneumatic means.

The illustrated sorting apparatus consists of 'base 10 which is adapted to be connected with or form a part of a complete sorting machine such as used with optical or magnetic character reading machines, punched card equipment (e.g. collators, readers, punches, etc.), postal letter sorting equipment, and others. An input path 12 for articles exemplified at 14 (FIGURE 1) is established by a part of the top surface of base 10 to which a pair of sidewalls 16 and 18 are fixed by conventional means. The walls are parallel and spaced from each other in the region of the input path, and they have curvatures at one end to form an entrance to accept articles, e.g. by being aligned with a conventional article feeder (not shown). Walls 16 and 18 have parts 17 and 19 which diverge from each other to define an article path transition station 20 between the juncture of branch paths 22 and 24 and the input path 12. The branch paths are established by parts of the surface of base 10 and the confronting surfaces of Walls 17 and 26 (for path 22) and walls 19 and 28 (for path 24). Branch paths 22 and 24 are designed to communicate with conventional destinations such as bins, pockets, stackers, etc. (not shown).

The walls 16 and 18 including their diverging parts 17 and 19 have slots 30 (one shown in FIGURE 2) to accept a pair of conveyor belts 32 and 34. These constitute the means for moving articles 14 along the input path 12 and into path transition station 20 in which each article is diverted into one of the branch paths 22 or 24. Belt 32 is entrained over three pulleys 36, 38 and 40 mounted on shafts 42, 44 and 46 (FIGURE 2) supported in bearings 48 attached to base 10. As shown in FIGURE 1 a portion of the periphery of each of the pulleys 36 and 38 passes through slot 30 and is located within the article inlet path 12. A part of the periphery of pulley 40 is disposed at the entrance to branch path 24. There is an identical set of pulleys 36a, 38a and 40a for the belt 34. Although we have shown belts 32 and 34 as rings, other conventional belts may be used. In fact, other conveyors can be used, for instance, we can use a series of rollers in place of the simpler belt and pulley system illustrated in FIGURES 1 and 2. Regardless of the type of conveyor used, it is operated by conventional means (FIG- URE 2) such as motor 50 with a switch-controlled energizing circuit 52. The shaft of motor 50 is attached to shaft 42 or, if desired, shaft 42 can be the armature shaft of motor 50. Both belts 32 and 34 are operated synchronously by a set of enmeshed gears 52 (only one gear shown in FIGURE 2) secured to shaft 42 and to shaft 42a for pulley 36a.

As shown in FIGURE 1, article 14 is moved along inlet path 12 by engagement with the confronting flights of the conveyor belts 32 and 34. The forward portion or leading edge of the article enters the transition station 20 and is diverted to the right or to the left depending on the direction of rotation of rotary diverter 54. The rotary diverter can have a continuous surface, e.g. rubber (not shown) or can resemble a gear or sprocket, that is, with peripheral teeth or projections 56 and recesses 58 between adjacent projections. The former frictionally deflects and the latter positively deflects articles. If article 14a is to be diverted into branch path 22, for example (FIGURE 2) diverter 54 will be rotating in a clockwise direction as the leading edge of the article engages the periphery of the diverter. As a consequence, article 14a is deflected (as shown) while it continues to be moved through station 20 by belts 32 and 34. When the leading edge of article 14a reaches the entrance to branch path 22, it is accepted between a part of belt 34 and the adjacent idler 58. Since the belt 34 is driven, article 14a is propelled into branch path 22 and is taken away by conventional means to be deposited in a destination bin, pocket, stacker, etc. It is evident from FIGURE 1 that if the article is to be diverted into branch path 24, diverter of 54 will be operating in the counterclockwise direction for deflecting the leading portion of the article between a part of belt 32 and the adjacent idler 60 at the entrance to path 24. The idlers 58 and 60 are suitably mounted in the positions illustrated, for example, by means of spindles 63 (FIGURE 2) attached to base 10. If desired, spindles 63 can be pivotally mounted on base and spring biased toward pulleys 40 and 40m so that idlers 58 and 60 can yield for thick articles. Diverter 54, on the other hand, must be driven clockwise or counterclockwise and for this purpose we have shown the diverter 54 attached to shaft 62. The latter is secured to or integral with the armature shaft of a conventional reversible motor 64. Shaft 62 is mounted in suitable bearings on base 10, and the motor 64 is secured by conventional means (not shown) to base 10. The direction of rotation of motor 64 is selected by electrical command signals emanating from any applicable source, and to represent this we have shown two lines 68 and 70 and a flip-flop 72 whose outputs on lines 74 and 76 are amplified and impressed on reversible motor 64. A signal on line 68 sets the flip-flop 72 in a manner such that motor 64 is operated in a clockwise direction. A signal on line 70 actuates flip-flop 72 to cause the motor 64 to operate in a counterclockwise direction. The timing of the signals on line 68 and 70 is such that the motor 64 and driven diverter 54 respond in ample time for diverting the article (e.g. as the article begins to enter the transition station 20) from its input path 12 to the preselected branch path 22 or 24.

Attention is now directed to the pneumatic system, a feature of which is that it is valveless. The pneumatic system consists of a conventional reversible blower 80 driven in directional synchronization with diverter 54. This is accomplished most simply by operatively connecting blower 80 to the shaft 62 of motor 64 which operates diverter 54 in the clockwise or counterclockwise direction. Air conductors or conduits 82 and 84 are connected with the two ports of blower 80 and terminate in communication with ports 86 in the parts 17 and 19 of the Walls 16 and 18. Any number and configuration of ports 86 can be used, however, their location is important. The ports 86 communicate with the transition station 20 as shown in FIG- URE 1. The arrangement is such that when the diverter 54 is operated in a clockwise direction, air conductor 84 becomes a pressure conduit and air conductor 82 becomes a suction conduit, i.e. the return to blower 80. When the diverter 54 is operated in the counterclockwise direction, the air conductors 84 and 82 exchange functions, that is, air conductor 82 becomes a pressure line while conductor 84 becomes a return or suction line. Alternatively, blower 80 can have a single inlet, while either conductor 82 or 84 becomes a pressure outlet line depending upon the direction of rotation of the rotor of the blower. The pneumatic action on the article in the transition station is to pneumatically deflect the article toward the entrances of the pre-selected branch path 22 or 24.

OPERATION The articles to be sorted are fed into the inlet path 12 (FIGURE 1) and moved toward the path transition station 20 by being engaged between the confronting flights of belts 32 and 34 within path 12. At the proper time in the travel of an article along path 12 (depending on the spacing between conveyed articles) a sort command signal is impressed on line 68 or line 70 causing motor '64 to operate clockwise or counterclockwise depending upon the desired destination of the article. This, in turn, causes diverter 54 to rotate clockwise or counterclockwise.

Since our pneumatic system is optional, the operation will be described first on the assumption that the pneumatic system is not present or is not used. Therefore, referring to FIGURES 3-3b, article 14b is shown being propelled into the transition station 20. The leading edge of the article is shown entering a peripheral recess between adjacent projections of diverter 54 which is rotating in a clockwise direction (FIGURE 3). As the article 14b (FIGURE 3a) continues to move by the action of the conveyor, the diverter deflects its leading edge toward the entrance to branch path 22 defined by pulley 40a and idler 58. On the other hand, if article 14b were to be sorted via branch path 24, a counterclockwise command signal will have been impressed on flip-flop 72. This would cause motor 64 to operate in a counterclockwise direction thereby rotating diverter 54 in a similar direction. As shown in FIGURE 3b the leading edge of article 14b would then have been diverted as it was contacted by diverter 54, toward and into the entrance of branch path 24 schematically represented by pulley 40 and idler 60.

Attention is now directed to FIGURES 4 and 4a showing the operation when the pneumatic system is used in conjunction with rotary diverter 54. When the diverter is rotated in the clockwise direction to sort the article via branch path 22, air conductor 84 conducts air under pressure against one surface of article 14b while air conductor 82 becomes the air inlet line for the reversible blower 80. Accordingly, the article is pneumatically deflected as shown in dotted lines in FIGURE 4. Depending on the pneumatic forces, stiffness of the article and speeds, article diverting can be only slightly or greatly influenced by the pneumatic forces. In other words, there may be situations in which articles are almost completely or completely pneumatically diverted at the article path transition station 20. In most cases, however, the mechanical diverter 54 will be responsible for directing the documents toward the pre-selected branch path by clockwise rotation (FIG- URE 4) of the diverter or counterclockwise rotation (FIGURE 4a) of the diverter.

It is understood that the preceding description of the illustrated forms of the invention is given by way of example only. For instance, a reversing motor 64 is illustrated as the means for rotating the diverter and actuating the blower in directionally synchronized motions. It is manifest that an identical result can be accomplished by using a single direction electric motor for driving shaft 62 through a pair of clutches and a reversing gear.

We claim:

1. In an apparatus to sort articles, means defining an input path for the articles, and means defining first and second branch paths communicating with said input path at an article transition station; the improvement comprising a rotary diverter disposed at said transition station, directionally responsive drive means for actuating said rotary diverter selectively in clockwise and counterclockwise directions, said diverter having means for accepting a forward portion of an article and directing said portion toward one of said branch paths depending on the direction of rotation of said diverter, said drive means being directionally responsive to electrical control signals, means for impressing electrical signals on said drive means, and bi-directional pneumatic means actuated by said drive meansand operable at said transition station for urging the article toward a selected branch path.

2. The subject matter of claim 1 wherein said pneumatic means include a reversible blower provided with a pair of air conductors to blow air against either side of the article depending upon the direction of motion of said drive means.

3. In an apparatus to sort articles, means defining an input path for the articles, and means defining first and second branch paths communicating with said input path at an article transition station; the improvement compris' ing a rotary diverter disposed at said transition station, drive means for actuating said rotary diverter selectively in clockwise and counterclockwise directions, said diverter having means for accepting a forward portion of an article and directing said portion toward one of said branch paths depending on the direction of rotation of said diverter, said diverter having projections, and said accepting means consisting of the confronting surfaces of said projections which define recesses in the diverter to accept the forward portion of the article.

4. The subject matter of claim 3 wherein said drive means include a motor, bi-directional pneumatic means driven by said motor and directionally synchronized with and second branch paths communicating with said input path at an article transition station; the improvement comprising a rotary diverter disposed at said transition station, directionally controllable drive means continusally rotating said rotary diverter through complete revolutions of rotation in a clockwise direction so long as articles moving along said input path are to be diverted toward said first branch path and continually rotating said rotary diverter through complete revolutions in a counterclockwise direction so long as articles moving along said input path are to be diverted toward said second branch path, said drive means being directionally responsive to control signals, means to provide said control signals to cause .continuous rotational actuation of said rotary means in a selected clockwise or counterclockwise direction, and said rotary diverter having a plurality of recesses which confront the leading edges of successive articles entering said transition station to accept the leading edge of each article in a random one of said recesses and apply a force thereto to divert it toward the first or second branch path depending upon the direction of rotation of the diverter at the instant that the article edge enters a said recess.

6. The subject matter of claim 5 and bi-directional pneumatic means operable at said transition station and actuated concurrently with changes in direction of said rotary means to similarly change the direction of the effective operation of said bi-directional pneumatic means for urging said articles toward the same selected branch path as directed by said rotary diverter.

References Cited UNITED STATES PATENTS 2,526,916 10/1951 Turrall 271-71 X 2,563,498 8/1951 Skinner 271-64 3,166,313 1/1965 Rehm 271-71 X 3,205,741 9/1965 Haselow 27164 X 3,265,208 8/ 1966 Reniker 209-74 X 3,327,850 6/1967 Simmons 209-74 X 0 M. HENSON WOOD, JR., Primary Examiner RICHARD A. SCHACHER, Assistant: Examiner U.S. c1. X.R. 209-44; 271-71 

